Bulletin # 205 System 4 Board Replacement Page 1 of 5 Summary Products Affected Key Word Tags Tools/Equipment (If Required) Parts/Materials (If Required) Related Media Replacing the System 4 control board in the black plastic enclosure. All doors with the System 4 control board Sys4, Board Replacement Phillips Screw Driver, Flat Blade Screw Driver, terminal Screw Driver System 4 Control Assy, Per Door R00142000 Author Randy Meyer, Rev A M. Burzlaff Issue Date 12/12/2011 Status Active PLEASE READ THE ENTIRE BULLETIN BEFORE BEGINNING THE PROCEDURE The door main electrical supply must be locked out and tagged out before beginning this procedure. The control board contains capacitors that store electrical energy and you must allow 20 minutes for the capacitors to discharge before beginning this procedure. After the electrical supply has been locked/tagged out and the capacitors discharged, remove the incoming supply voltage from the System 4 control panel. Wires L1, L2, L3. (See Figure 1). Remove the wires from terminals T1, T2, T3. (See Figure 1). Figure 1 Remove the green/yellow (ground) wires from the ground bus. (See Figure 2). Note: Only the green/yellow wires from the System 4 board need to be removed from the ground bus. All other ground wire can remain. Figure 2
Bulletin # 205 System 4 Board Replacement Page 2 of 5 The remaining terminal blocks can be lifted off of the control panel. The terminals will have the same color and numbers as the pins on the control board. (See Figure 3). Figure 3 Note: The terminal blocks can also be rotated 90 degrees. The photo in figure 3 shows the mounting holes for the rotation. The control board is held in place with one screw located at the bottom of the board in the center, just to the right of terminal L3. Loosen this screw, the screw cannot fall out of the sleeve however, you will feel the screw bounce slightly when it is completely out of the hole. Grab the head of the screw and pull it slightly and it will move out a little more and lock into place. When the screw is out it will stand approximately ¾ out of the hole. (See Figure 4 & 5). Figure 4 Figure 5 Carefully pry the control board towards the floor and this will unlock the board from the plastic tabs holding the board in place. The back of the control board has a small foam gasket around the edge and may stick to the plastic enclosure. Use a large flat blade screw drive to pry the board loose. Firm pressure is required. You may hear a sound similar to sanding a piece of wood; this is the silicone gasket rubbing on the plastic enclosure. (See Figures 6, 7, 8).
Bulletin # 205 System 4 Board Replacement Page 3 of 5 Note: White paint is used for clarity. Actual controller will not have white paint. Screw driver prying board towards the floor. A large, long screwdriver may work best. Note: Photo showing silicone gasket on back side of the control board. It runs around the entire control board. Figure 6 Figure 7 Note: The control board has 6 clips that hold the control board in place. When the control board has been pried into the proper position you will see the tab completely inside the hole as shown in the photo. All 6 clips must be in this position to remove the control board. Figure 8 The control board can now be completely removed from the plastic enclosure. (See Figure 9). Figure 9
Bulletin # 205 System 4 Board Replacement Page 4 of 5 The new control board can now be installed. Place the new control board into the enclosure. Align the 6 holes with the 6 tabs.( See Figure 10 & 11). Figure 10 Figure 11 Figure 11 shows the 3 tabs in the 3 holes. The other side of the board should look the same. The board must now be slid into the final installation position. Place a screwdriver between the hole and the tab; gently pry the board towards the top of the plastic enclosure. Pry each side equally until the board is positioned under all the tabs. There are 8 total tabs, 3 on each side and 2 at the top. (See Figure 12 & 13). Figure 12 Figure 13 With the board in the correct position the screw can now be turned into position to hold the control board in place. NOTE: If the screw is not able to be turned in the board may not be in the proper position. Repeat the step above; be sure to pry each of the 6 areas equally until the final position is reached.
Bulletin # 205 System 4 Board Replacement Page 5 of 5 Replace the terminal blocks onto the control board. Connect the green/yellow (ground) wires to the ground bus (brass colored). Connect the motor leads T1, T2, T3. Connect supply voltage L1, L2, L3. Note: Install cover of the control panel before applying power to the control system. Remove the lock out; tag out and apply power the control. Follow the instructions on the display to set the door limits. Hint: Apply a very light coating of moisture to the silicone seal this will assist sliding the control board into position. Applying slight pressure to the control (towards the wall) will help to compress the silicone gasket and may make the control board easier to pry into position. If you have further questions contact Rytec Support at 1-800-628-1909